1、,生產(chǎn)件批準(zhǔn)程序 Production Part Approval Process (PPAP),Presented by: Max Zhang Ford CSO STA 9th August 2007,PPAP is to demonstrate suppliers understanding of:PPAP是為表明供應(yīng)商怎樣理解以下內(nèi)容的一個(gè)過(guò)程：,- 零件的用法 Parts Usage - 相關(guān)的項(xiàng)目 Associated programs - 車輛 Vehicle - 型號(hào)年份 Model Year (MY),零件的功能 Parts functionality,零件的特性 Parts

2、Characteristics,特性的關(guān)鍵性 Criticality of features,怎樣測(cè)量零件 How to gauge the part,生產(chǎn)要求 Production requirements,工程圖紙要求 Engineering drawing requirements 工程規(guī)范 (ES) 材料特性 Material Characteristics 材料處理(熱處理, 外觀) Material Treatment (Heat Treat, Appearance),安全特性 Operator Safety features, if any 關(guān)鍵特性 Critical Chara

3、cteristics 重要特性 Significant Characteristics 高影響的特性 High Impact Characteristics 傳遞特性 Pass Through Characteristics,使用哪些最為合適的量具 What most suitable gauges to use? - 計(jì)量型量具 Variable gauges - 計(jì)數(shù)型量具 Attribute gauges 基準(zhǔn) Datum 測(cè)量方法和裝配工廠存在相關(guān)性 Measurement Correlation with using plants,何時(shí)需要？ When needed? 哪里需要? W

4、here needed? 多少數(shù)量? How much? -按節(jié)拍生產(chǎn) Run at Rate -生產(chǎn)能力確認(rèn) Capacity Verification,Application什么時(shí)候用到PPAP?,PPAP is required for, but not limited to: PPAP對(duì)以下情況適用（但不局限于）： All new tooled parts （使用新模具生產(chǎn)零件） All new vehicle programs and running changes for vehicles currently in production (新車型，或者是對(duì)現(xiàn)有車型的變更) Any

5、change in supplier operating pattern (i.e. new shift) (生產(chǎn)模式的變更) Any additional, modified or reconfigured production tooling, equipment or work streams （模具，設(shè)備或生產(chǎn)線的增加，改造或重新裝配） Revised customer DPV (Daily Production Volume) exceeding verified supplier capacity level （客戶需求量的增加）,Content內(nèi)容,Phased PPAP int

6、roduction 階段性生產(chǎn)件批準(zhǔn)程序的介紹 Ford special requirements to PPAP 18 elements. 福特汽車對(duì)于生產(chǎn)件批準(zhǔn)18個(gè)項(xiàng)目的要求。 VPP usage VPP的使用方法,階段性生產(chǎn)件批準(zhǔn)程序PHASED PPAP PROCESS,What is the Phased PPAP?什么是Phased PPAP？,Phased PPAP is Fords approach to PPAP process management Phased PPAP是福特特有的生產(chǎn)件批準(zhǔn)管理程序。 Introduced to improve upon launch

7、performance 用來(lái)提高項(xiàng)目開(kāi)發(fā)和實(shí)施的表現(xiàn)。 Requires a supplier site to demonstrate Manufacturing capability （制造能力） Product quality （產(chǎn)品質(zhì)量） And production capacity （產(chǎn)能） prior to job #1 （在J#1之前）,Phased PPAP vs the old PPAPPhased PPAP與PPAP的比較,Phased PPAP organizes the process into four phases Phase 0: Run-at-Rate Phas

8、e 1: Quality Verification Phase 2: Production Verification Phase 3: Capacity Verification,PPAP,X,1 PP,FEU,Job 1,Phased PPAPPhase 0Phase 1Phase 2Phase 3,Supplier Phased PPAP Process Map階段性生產(chǎn)件批準(zhǔn)程序示意圖,STATUS:,Phase 2,Completed,Phase 2,Warrant,#18,Yes,Status Tracking,Database,2,3,4,Proceed to next page,

9、Submit to,Customer,Important note:,Phase 2 and Phase 3 can happen,concurrently if all Inputs and,Outputs are satisfied,No,Phase 0 Run-at-Rate,Phase 1 Quality Verification,Phase 2 Production Verification,Phase 3 Capacity Verification,1 - Design Records 2 - Engineering Change Documents 3 Customer Engi

10、neering Approval 4 - Design FMEA 5 - Process Flow Diagrams 6 - Process FMEA 7 - Control Plans 8 - Measurement System Analysis Studies 16 - Checking Aids 17 - Customer-Specific Requirements,9 - Dimensional Results 10 - Records of Material / Performance Test Results 11 - Initial Process Studies 12 - Q

11、ualified Laboratory Documentation 13 - Appearance Approval Report 14 - Sample Production Parts 15 - Master Sample 18 - PPAP Warrant,PPAP Warrant (element 18),Run-at-Rate for all production streams (element 1 8, 16, 17),Quality Verification for all production streams (element 9 15),Capacity Analysis

12、Report,Capacity Analysis Report,PPAP Warrant (element 18),Have Run-at-Rates (Phase 0) been conducted and Quality Verifications (Phase 1) been satisfied for ALL production streams?,Phase 0: Run-At-Rate （按節(jié)拍生產(chǎn)）,Phase 1 Prerequisites (Phase 1的先決條件）,In order to begin Phase 1, the following are required:

13、 要進(jìn)入Phase 1，必須達(dá)到以下條件： Successful completion of Run-at-Rate (Phase 0) for at least one work stream 對(duì)至少一條生產(chǎn)線成功完成節(jié)拍生產(chǎn) Capacity Analysis Report completed for at least one Job1-intended production work stream 對(duì)至少一條生產(chǎn)線成功完成產(chǎn)能分析 Tier “X” successful completion of Phase 1 分供方完成了Phase 1 PPAP.,Phase 1: Quality

14、Verification (質(zhì)量驗(yàn)證）,1,Continue Production Part Approval Process (PPAP) using parts from Phase 0 Dimensional measurements #9 Material tests #10 Statistical process package #11 Performance tests #12 Appearance criteria #13 Sample parts #14 Master samples #15 Customer-specific requirements #17 As defin

15、ed by PPAP,Return toPhase 0 for corrective action,STATUS: Phase 1 Complete,Phase 1 Warrant #18,Status Tracking Database,4,2,NO,Submitto customer,YES,Have the PPAP elements been satisfied?,Important note: for suppliers with only one production stream, completion of Phase 1 & 2 occur at the same time.

16、,4,What is required to get Phase 1 PSW approval?獲得Phase1 PSW的條件,Input Requirements （Phase 2的先決條件）,Phase 2 requires the following （Phase2需要以下條件）: All Job 1 intended production work streams have successfully completed Run-at-Rate （所有生產(chǎn)線都成功完成了節(jié)拍生產(chǎn)） Capacity Analysis Reports completed for all Job 1 inte

17、nded production work streams （所有生產(chǎn)線都成功完成了產(chǎn)能驗(yàn)證） Tier X successful completion of Phase 2 (分供方完成Phase 2 PPAP).,Page 51 Define Tier X and include note requesting addl info for script due to sound,Phase 2: Production Verification （生產(chǎn)驗(yàn)證）,2,STATUS: Phase 2 Complete,Phase 2 Warrant #18,Status Tracking Datab

18、ase,3,NO,Submitto customer,YES,Have Run-at-Rates (Phase 0_ been conducted and Quality Verifications (Phase 1) been satisfied for ALL streams?,Important note: Phase 2 and Phase 3 can happen concurrently if all inputs and outputs are satisfied.,4,Phase 3: Capacity Verification,3,Ford Special Requireme

19、nts to PPAP 18 Elements福特對(duì)生產(chǎn)件批準(zhǔn)18個(gè)要素的要求,Design Record 設(shè)計(jì)記錄,The design must be released and authorized by Ford D&R. 總成圖必須獲得福特設(shè)計(jì)工程師的批準(zhǔn)，并在福特系統(tǒng)中(WERS)發(fā)布。 Where the design record is in electronic format, the organization shall produce a hard copy (e.g., GD&T drawing) to identify measurements taken. 當(dāng)設(shè)計(jì)記錄

20、(如CAD/CAM數(shù)模、零件圖紙、技術(shù)規(guī)范)是以電子格式（如數(shù)模）存在時(shí)，供應(yīng)商必須復(fù)制一份硬拷貝（如示意圖、幾何尺寸和公差表、圖紙）以標(biāo)識(shí)測(cè)量的內(nèi)容。 Engineering change level properly indicates the latest design change. 工程變更等級(jí)必須符合最新的設(shè)計(jì)變更狀態(tài) For FSS, if the parts are identified as black box, the design record should at least specifies the interface and performance requirem

21、ents. (e.g. Vehicle Assembly Position). 對(duì)全服務(wù)供應(yīng)商，對(duì)于定義為黑盒子的零件，設(shè)計(jì)記錄要規(guī)定和其他件配合的關(guān)系和性能要求。,2. Engineering Change Documents 工程變更文件,SREA signed by CFT. 供應(yīng)商工程變更申請(qǐng) WERS Concern. - 如果有權(quán)限進(jìn)入WERS，供應(yīng)商可以通過(guò)WERS Concern來(lái)提交設(shè)計(jì)變更 - 福特提出的設(shè)計(jì)變更通過(guò)WERS Concern來(lái)通知供應(yīng)商和內(nèi)部相關(guān)人員 WERS = World Engineering Release System,3. Customer En

22、gineering Approval 客戶工程批準(zhǔn),The organization shall obtain documented Ford Product Development engineering approval of DV (Design Verification) and PV (Production Validation) tests of the initial sample parts. 供應(yīng)商必須獲得福特PD部門對(duì)D/PVP&R的書(shū)面批準(zhǔn)。 The organization shall conduct the PV testing on parts/products w

23、hich were produced at “run at rate”. （使用節(jié)拍生產(chǎn)出來(lái)的零件進(jìn)行PV試驗(yàn)） Where appropriate, Ford Engineering records initial sample part approval on the ESER/ESO. 工程批準(zhǔn)的方式可能有很多：ESER, ESO, DVP&R WERS Alert for Interim-Approval. 臨時(shí)批準(zhǔn)需要有WERS Alert支持。,4. DFMEA 設(shè)計(jì)不良模式效應(yīng)分析,When developing FMEA, the requirements of Ford FM

24、EA handbook (special characteristic definition) shall be met. 有產(chǎn)品設(shè)計(jì)職責(zé)的組織，必須按照福特的FMEA手冊(cè)開(kāi)發(fā)設(shè)計(jì)FMEA。 For parts with YC/CC, DFMEAs must be approved in writting by Ford D&R engineer. 如果零件有關(guān)鍵特性（YC/CC,車輛安全規(guī)范或政府法規(guī)控制），DFMEA要獲得福特設(shè)計(jì)工程師的書(shū)面確認(rèn)。 Ford reserves the right to review and approve all organization-develope

25、d DFMEAs. 福特保留審核和批準(zhǔn)供應(yīng)商開(kāi)發(fā)的DFMEA的權(quán)利。 Over patent concerns, sometimes, supplier does not wanna share DFMEA, we could review it at the supplier site or have the supplier bring them to our office. （現(xiàn)場(chǎng)審核DFMEA硬拷貝）,5. Process Flow Diagram 過(guò)程流程圖,制造過(guò)程繪制 Mapping the Manufacturing Process. 組隊(duì) Organize the team

26、制作過(guò)程流程圖 Develop A Process Flow Diagram 確定每一過(guò)程的偏差來(lái)源 Identify sources of variation in each process 結(jié)合經(jīng)驗(yàn)教訓(xùn) Incorporate lessons learned 記述各個(gè)步驟的目的 Describe purpose of each step,5. Process Flow Diagram 過(guò)程流程圖,6. PFMEA 過(guò)程FMEA,General Procedure to develop PFMEA: 編制過(guò)程FMEA的一般流程 Ask the questions: 哪些方面可能會(huì)出現(xiàn)錯(cuò)誤？

27、What can go wrong? 如果發(fā)生了會(huì)怎樣！產(chǎn)生什么影響？ So what ! Effect ? 不產(chǎn)生功能 No function 產(chǎn)生部分功能 Partial 出現(xiàn)不需要的功能 Unintended function 原因？ Cause (s)?,6. PFMEA 過(guò)程FMEA,General Procedure to develop PFMEA: 編制過(guò)程FMEA的一般流程(續(xù)) 當(dāng)此情況發(fā)生需要采取何種措施？ What do we do when this happens? 來(lái)預(yù)防故障 To prevent the failure 來(lái)發(fā)現(xiàn)故障 To detect the f

28、ailure 假如還不夠， 那么： If that is not enough, then: 還需要做什么？ What else need to be done?,6. PFMEA 過(guò)程FMEA,Process FEMA Output 過(guò)程FEMA 輸出： 哪些需要被控制 What needs to be controlled 對(duì)于產(chǎn)品和過(guò)程來(lái)說(shuō)哪些是關(guān)鍵的？ What is critical in the product & the process 怎樣來(lái)控制這些 How to control these things,6. PFMEA 過(guò)程FMEA,If DFMEA does not ex

29、ist, the team must have a meeting with the Design Engineer - using the CRT approach. 如果沒(méi)有DFMEA，供應(yīng)商需要和福特設(shè)計(jì)工程師確定關(guān)鍵特性和顯著特性的清單。 For parts with CC, PFMEAs need to get Ford Engineering & STA Approval. 對(duì)有關(guān)鍵特性的零件，PFMEA要獲得福特PD和STA的批準(zhǔn)。 Characteristic traceability is required from the DFMEA through the PFMEA t

30、o the Control Plan (Supp.K). 要保證特殊特性在各個(gè)文件中的一致性。 Error Proving list is one output of PFMEA. 防錯(cuò)清單是PFMEA的一個(gè)重要輸出。 PFMEA is living document. (8D, SREA) PFMEA要不斷更新。,7. Control Plan 控制計(jì)劃,對(duì)過(guò)程按從開(kāi)始到結(jié)束的邏輯順序 Documenting the logical order of processes, start to finish 說(shuō)明產(chǎn)品特性及過(guò)程參數(shù) Specify product characteristics

31、and process parameters 對(duì)什么進(jìn)行控制及怎樣控制 What to control & how 何時(shí)進(jìn)行控制及控制程度 When to control & how much 如遇故障，下步需做什么 What to do, if all failed,7. Control Plan 控制計(jì)劃,CC/SC list is properly cascaded in to CP. 控制計(jì)劃要體現(xiàn)對(duì)特殊特性的有效控制。 Incoming Inspection is the 1st part of CP. 來(lái)料檢驗(yàn)是控制計(jì)劃的第一部分。 The Reaction Plan should

32、 be evaluated for effectiveness and use. 評(píng)估應(yīng)變計(jì)劃以驗(yàn)證其有效性 Lists all process parameters and part characteristics that require specific quality planning actions. 對(duì)產(chǎn)品特性和過(guò)程特性都要規(guī)定有效的控制措施 STA approval. STA批準(zhǔn)（對(duì)CC件，要獲得福特PD和STA批準(zhǔn)） Living documentation. （根據(jù)變更和8D更新控制計(jì)劃）,7. Control Plan 控制計(jì)劃,8. Measurement System

33、Analysis 測(cè)量系統(tǒng)分析研究,All gauges (both general or dedicated) in Control Plan. 無(wú)論測(cè)量系統(tǒng)的類型是什么，用于檢查福特產(chǎn)品的所有量具,都需進(jìn)行量具再生/再現(xiàn)性分析。 MSA 3.0 based. 基于MSA3.0版本 Associated % tolerance and % study variation. 在總偏差中的量具誤差占公差的比例和過(guò)程變差的比例。 To variable gages, the parts used for the Gauge R&R study must be within Design Recor

34、d specifications. 對(duì)計(jì)數(shù)型量具，用于MSA的零件必須符合設(shè)計(jì)規(guī)范。 The acceptance criteria for Gauge R&R as a percent of TOLERANCE is less than 10%. If %tolerance is over 10% customer approval is needed. The Gauge is unacceptable if % tolerance is over 30%. NDC more than 5. ANOVA Method preferred with Minitab. （優(yōu)先使用方差方法）,9

35、. Dimensional Results 全尺寸報(bào)告,Dimensional Measurements to compare the actual part with the drawing (bubble prints). Default are 3 parts measured (5 pcs preferred). 比較實(shí)際零件是否符合設(shè)計(jì)記錄的要求，默認(rèn)三件。 If production parts will be produced from more than one cavity, mold, tool, die, pattern or production process, a

36、dimensional evaluation on one part from each should be completed. 對(duì)于每個(gè)獨(dú)立加工的過(guò)程，如：生產(chǎn)單元或生產(chǎn)線，和所有的多模腔、成型模、模型或沖模，都必須有全尺寸測(cè)量結(jié)果。 Make one of the parts measured as Master Sample“. 將其中一個(gè)零件作為標(biāo)準(zhǔn)樣品,10. Material/Performance Test Results 材料/性能試驗(yàn)結(jié)果的記錄,Where Ford specifies that materials are to be purchased from an a

37、pproved supplier, the organization should contact the buyer to determine appropriate materials suppliers. 對(duì)特殊材料必須選擇福特指定的供應(yīng)商。 Ford PD is supposed to approve the PV test plan, and to sign the PVP&R. PV試驗(yàn)計(jì)劃要獲得福特PD的確認(rèn)。PV試驗(yàn)成功完成后，PD要在PVP&P上簽字。 All PV test requirements are clearly identified in the DVP&R.

38、(PVP&R) D/PVP&R中必須規(guī)定試驗(yàn)設(shè)備。 PV testing is supposed to use run at rate parts. PV試驗(yàn)的零件來(lái)自節(jié)拍生產(chǎn) All test equipment used for PV Testing is available and in the appropriate location (fully calibrated and certified). 試驗(yàn)設(shè)備要經(jīng)過(guò)校準(zhǔn)和確認(rèn)。,11. Initial Process Study 初始過(guò)程研究,MSA should be conducted before Ppk study. 在進(jìn)行初

39、始過(guò)程研究之前，必須確保量具已經(jīng)做過(guò)MSA。 Ppk is required for Initial Process Study, SCs and CCs must meet at minimum 1,67 Ppk. 特殊特性要滿足Ppk=1.67的要求。 Focus on variables data. 針對(duì)計(jì)數(shù)性數(shù)據(jù) If Ppk =1.67的條件，必須采用防錯(cuò)或者100%檢測(cè)來(lái)控制該特性。,Cpk or Ppk?,Cpk is to determine if the process is capable to meet specifications, and is a predictio

40、n of what your process can do. The process has to be in statistical control. At leat 100 individual samples available.,when you cant determine statistical control or if you are looking at a very short production run, Ppk should be used.,12. Qualified Lab Documentation 合格的實(shí)驗(yàn)室文件,The qualified laborato

41、ry (internal or external) shall have a laboratory scope and documentation to show it is qualified to conducted the inspection and testing for PPAP. 組織必須有一份實(shí)驗(yàn)室范圍和說(shuō)明所使用的實(shí)驗(yàn)室遵循的證明文件。 The external laboratory shall be in compliance with the latest ISO/IEC 17025 (or national equivalent). 外部實(shí)驗(yàn)室要符合最新ISO/IEC

42、17025的要求 （或所在國(guó)等同要求）,13. Appearance Approval Report 外觀批準(zhǔn)報(bào)告,All parts/products having appearance criteria shall be reviewed and approved by the appropriate Ford activity (Design Quality). 當(dāng)產(chǎn)品和零件在設(shè)計(jì)記錄上有外觀要求且要求提交時(shí)，則每一個(gè)零件或零件系列都必須填寫(xiě)一份單獨(dú)的外觀批準(zhǔn)報(bào)告（AAR）。 Appearance approval includes, but is not limited to: ove

43、rall appearance, surface quality, color, texture, and gloss. 外觀批準(zhǔn)包括整體外觀，表面質(zhì)量，顏色，皮紋和光澤度等等。 Visual match-to-master is the specified requirement for AAR sign-off. Numeric evaluations should only be used for on-going quality control after visually acceptable parts/products are attained. AAR是福特精致工藝部門參照外觀

44、標(biāo)準(zhǔn)對(duì)零件的視覺(jué)比較（主觀的）。計(jì)量型評(píng)價(jià)方法只可以作為生產(chǎn)過(guò)程控制的方法來(lái)使用，但必須在獲得AAR之后。 AAR plan and Pre-AAR.,14. Sample Production parts 生產(chǎn)件樣品,Customer defines the quantity. 客戶規(guī)定生產(chǎn)件樣品的數(shù)量。 Sample Parts are needed for the parts functioning in the Vehicle or Powertrain Assembly。 生產(chǎn)件樣品用來(lái)在整車廠或發(fā)動(dòng)機(jī)廠作功能性裝車試驗(yàn)。 Photos as evidence is acceptab

45、le. 可以使用照片作為證據(jù)。,15. Master Sample 標(biāo)準(zhǔn)樣件,Master sample which is retained in the suppliers site for reference. Master sample has the same life as PPAP package. 標(biāo)準(zhǔn)樣件由供應(yīng)商負(fù)責(zé)保管，保存期與生產(chǎn)零件批準(zhǔn)文件的保存期相同 。 Supplier shall retain a master sample from each position of a multiple cavity die, mold, tool or partern, or

46、production process unless otherwise sepcified by the customer. 組織必須保存一份由多腔模具、鑄模、工裝、仿形?；蛏a(chǎn)過(guò)程的每一腔模具生產(chǎn)的樣件。 Customer (STA&PD) signature with approval date. 標(biāo)樣必須標(biāo)識(shí)顧客批準(zhǔn)標(biāo)樣的日期。 Dimensional Result is required form Master Sample 標(biāo)準(zhǔn)樣件要有全尺寸報(bào)告,16. Checking Aids 檢查輔具,Gauge strategy and drawing approved by custome

47、r. 專用檢具和特殊工裝的圖紙。檢驗(yàn)輔具可以是零件專用檢具，包括卡具、量規(guī)、模形、模版及聚酯薄膜。 The gauges are to the latest design level. 檢具必須符合零件的最新設(shè)計(jì)狀態(tài)。 MSA study to checking fixtures is required. 對(duì)專用檢具要做MSA分析。,17. Customer Specific Requirements客戶特殊要求 -Packaging Approval 包裝批準(zhǔn),Expendable Package VS. Returnable Dunnage. 一次性包裝 VS. 可回收包裝 Forms:

48、表格 - FoE&FAP: FORM 1121 (via FSBC) 福特歐洲和亞太：1121表 （福特澳洲通過(guò)FSBC提交） - NA: FORM 150E 福特北美：150E表 Trial shipment that simulates the production logistics process. (Water Shipment Trial for exporting suppliers) 如果使用福特指定的物流商，供應(yīng)商需要完成海運(yùn)試驗(yàn)來(lái)支持包裝批準(zhǔn)。,17. Customer Specific Requirements- Capacity Verification （產(chǎn)能驗(yàn)證）,

49、Measure the ability of a supplier to meet Ford Motor Companys Capacity Planning Volume (CPV) with quality parts, on time. 目的是驗(yàn)證供應(yīng)商能否滿足福特產(chǎn)能的要求。 Capacity verification to each work station to identify the bottleneck process 產(chǎn)能驗(yàn)證要細(xì)化到每個(gè)工位來(lái)識(shí)別瓶頸工序。 CPV information should be provided by buyer. 福特采購(gòu)部門提供計(jì)劃產(chǎn)能信息。,17. Customer Specific Requirements - Supplement-K & IMDS - K表和國(guó)際材料數(shù)據(jù)系統(tǒng),Supp.K is used to demonstrate the linkage between the Drawing - FMEAs - Control Plans - Operator Instruction Sheets. K表用來(lái)驗(yàn)證不同文件（圖紙，DFMEA，PFMEA，控制計(jì)劃和操作指導(dǎo)書(shū)）之間的聯(lián)接性 All material need to comply to requirement of WS